Patent Application
20240228387
The present disclosure relates to a polycrystalline cubic boron nitride (PCBN) body, a method for manufacturing the body, and use of the same.
Current tooling solutions for machining difficult materials such as heat resistant nickel based or cobalt based super alloys (HRSA), are limited to the use of coated cemented carbide tools usually operating at relatively low cutting speeds. This is today the common practice in aerospace manufacturing industry.
Main wear morphologies found when machining HRSA alloys are crater wear, flank/nose wear, notching, cracking, chipping, plastic deformation, and catastrophic failure. Cratering is often attributed to diffusion or dissolution wear mechanisms where a smooth worn surface is observed. Additionally, abrasion is coupled to flank wear development due to tool material softening at elevated cutting temperatures. The flank portion of a cutting tool is subjected to workpiece contact movement and flank wear, which will lead to poor surface quality of the workpiece, inaccuracy in the cutting process and increased friction as the cutting proceeds. Cutting tools of polycrystalline cubic boron nitride (PCBN) can maintain high hardness at elevated temperatures and therefore gain an increasing popularity when machining HRSA alloys.
With the increasing demand for improved productivity, for example, by increasing cutting speeds or having higher metal removal rate, in aeroengine manufacturing, alternative solutions to coated cemented carbide have emerged and can be used in semi-finishing applications for high-speed machining of HRSA alloys. Examples of alternative solutions used today are PCBN cutting tools with a titanium carbide (TiC)- or titanium carbide nitride (TiCN)-based binder.
Yet, PCBN materials have a higher cost compared to cemented carbide materials and to be cost-effective there is a need to demonstrate even higher productivity than with conventional PCBN solutions having TiC or TiCN as a binder.
Patent application WO2011098556 A1 discloses an example of a PCBN material having a conventional binder phase comprising TiC or TiCN. As a deviation from conventional PCBN composition the patent application EP3239116 A1 shows a PCBN sintered body having 40-85 volume percent (vol %) cBN and 15-60 vol % binder phase. The binder phase has the main constituent of aluminum (Al) compounds such as Al2O3, AlN and an additive of zirconium (Zr) oxide compounds such as zirconium oxide (ZrO), and zirconium dioxide (ZrO2) in an amount of up to 10 vol % of the whole cubic boron nitride sintered body.
To meet the above demands, there is a need for new PCBN material that can be used for a body of a cutting tool, and where the PCBN material has advanced properties to improve tool-life during machining operations. When a better flank wear resistance and/or notch wear resistance is obtained, an extended tool life will be obtained for some machining applications and operations.
It is an aim of the present invention to provide a sintered PCBN body having improved performance in machining operations.
This aim is achieved by a PCBN body as defined in claim 1 and by the method of claim 14.
The disclosure provides a sintered polycrystalline cubic boron nitride (PCBN) body comprising between 40 and 85 vol % of cubic boron nitride (cBN) particles and between 15 and 60 vol % of a binder phase, wherein the binder phase comprises at least one metal oxide and at least one metal nitride, wherein the at least one metal oxide comprises between 20 and 100 vol % of zirconium oxide (ZrO2) and up to 80 vol % of alumina (Al2O3) counted as a volume percentage of the total metal oxide content of the binder, the at least one metal nitride comprises aluminium nitride (AlN) and at least one metal nitride selected from the group consisting of vanadium nitride (VN), niobium nitride (NbN) and hafnium nitride (HfN), and that the metal nitride content is at least 10 vol % of the binder phase. Therewith a PCBN body having improved performance in machining operations is obtained.
The disclosure also provides a sintered polycrystalline cubic boron nitride (PCBN) body comprising between 40 and 85 vol % of cubic boron nitride (cBN) particles and between 15 and 60 vol % of a binder phase, wherein the binder phase comprises at least one metal oxide and at least one metal nitride, wherein the at least one metal oxide comprises between 20 and 100 vol % of zirconium oxide (ZrO2) and up to 80 vol % of alumina (Al2O3) counted as a volume percentage of the total metal oxide content of the binder, the at least one metal nitride comprises aluminium nitride (AlN) and at least one metal nitride selected from the group consisting of vanadium nitride (VN), niobium nitride (NbN) and hafnium nitride (HfN), and that the metal nitride content selected from said at least one of vanadium nitride (VN), niobium nitride (NbN) and hafnium nitride (HfN) constitutes at least 10 vol % of the total binder phase, and wherein said at least one metal oxide constitutes at least 10 vol %, preferably for example at least 20 vol % or at least 30 vol %, or at least 40 vol %, or at least 50 vol %, or at least 60 vol % of the total binder phase.
According to one embodiment, the content of AlN in the sintered polycrystalline cubic boron nitride (PCBN) body ranges from 1 to 10 vol %, such as from 1 to 7 vol %, for example 2 to 6 vol % or 3 to 5 vol % of the total binder phase. According to some aspects the binder phase of the PCBN body further comprises at least one metal oxynitride being a reaction product of one of the at least one metal oxides and one of the at least one metal nitrides. In other words when the binder phase comprises at least one metal oxynitride, the at least one metal oxynitride is a reaction product of a metal oxide selected from the group consisting of ZrO2 and Al2O3, and a metal nitride selected from the group consisting of VN, NbN and HfN. Tests have shown that the average tool life of a PCBN body having a binder phase according to the above disclosed composition is increased compared to prior art solutions with other types of binder phase compositions. When the binder phase of the PCBN body has a composition according to the above disclosed composition a higher flank wear resistance as well as higher notch wear resistance during machining is obtained compared to prior art solutions, when the same cutting parameters are used.
According to some aspects the PCBN body comprises between 50 and 75 vol % of cBN particles, preferably between 60 and 75 vol % of cBN particles, even more preferably between 60 and 70 vol % of cBN particles.
According to some aspects the PCBN body comprises between 25 and 50 vol % of a binder phase, preferably between 25 and 40 vol % of a binder phase, even more preferably between 30 and 40 vol %.
According to some aspects, the content of cBN particles and binder phase in the PCBN body is up to 100 vol % of the PCBN body.
According to some aspects, the content of metal oxide, metal nitride and metal oxynitride in the binder phase is up to 100 vol % of the binder phase.
According to some aspects, the binder phase comprises at least one oxynitride selected from the group consisting of zirconium oxynitride (Zr(O,N)), zirconium vanadium oxynitride ((Zr,V)ON), zirconium niobium oxynitride ((Zr,Nb)ON) and zirconium hafnium oxynitride ((Zr,Hf)ON).
According to some aspects, the binder phase comprises at least one oxynitride selected from the group consisting of aluminium oxynitride (Al(O,N)), aluminium vanadium oxynitride ((Al,V)ON), aluminium niobium oxynitride ((Al,Nb)ON) and aluminium hafnium oxynitride ((Al,Hf)ON).
According to some aspects, the binder phase consists of ZrO2, Al2O3, AlN and at least one metal nitride selected from the group consisting of VN, NbN and HfN.
According to some aspects, the metal nitride selected from the group consisting of VN, NbN and HfN constitutes up to 60 vol % of the total binder such as up to 50 vol % of the total binder phase, for example up to 40 vol % or up to 30 vol % or up to 20 vol % of the total binder phase. By having up to 60 vol % or up to 50 vol % or up to 40 vol % or up to 30 vol % or up to 20 vol % of the total binder phase being a metal nitride from the group consisting of VN, NbN and HfN, the material mechanical properties and cutting edge chipping resistance are improved compared to a binder comprising only metal oxide phases.
According to some aspects, the metal nitride selected from the group consisting of VN, NbN and HfN constitutes between 10 and 50 vol % of the total binder phase. By having between 10 and 50 vol % of the total binder phase being a metal nitride from the group consisting of VN, NbN and HfN the material mechanical properties and cutting edge chipping resistance are improved compared to a binder comprising only metal oxide phases.
According to one embodiment, the metal nitride selected from the group consisting of VN, NbN and HfN constitutes at least 20 vol % or at least 30 vol % or at least 40 vol % of the total binder phase.
According to one embodiment, said at least one metal oxide and the aluminium nitride together, the content of the aluminium nitride being as further specified herein, constitute up to 90 vol % or up to 80 vol % or up to 70 vol % or up to 60 vol % or up to 50 vol % or up to 40 vol % or up to 30 vol % or up to 20 vol % of the total binder phase.
According to some aspects, the binder phase consists of ZrO2, Al2O3, AlN, at least one metal nitride selected from the group consisting of VN, NbN and HfN, and at least one oxynitride from the group consisting of: Zr(O,N), (Zr,V)ON, (Zr,Nb)ON, (Zr,Hf)ON, Al(O,N), (Al,V)ON, (Al,Nb)ON and (Al,Hf)ON. Tests have shown that the average tool life of a PCBN body comprising a binder phase consisting of ZrO2, Al2O3, AlN, at least one metal nitride selected from the group consisting of: VN, NbN and HfN, and at least one oxynitride from the group consisting of: Zr(O,N), (Zr,V)ON, (Zr,Nb)ON, (Zr,Hf)ON, Al(O,N), (Al,V)ON, (Al,Nb)ON and (Al,Hf)ON is increased compared to prior art solutions with other types of binder phase compositions.
According to some aspects, the oxynitride and metal nitride are between 10 and 50 vol % of the total binder phase of the PCBN body. Preferably the oxynitride and metal nitride are between 25 and 50 vol % of the total binder phase of the PCBN body.
According to some aspects, the ZrO2 is between 20 and 90 vol % of the total metal oxide content of the binder phase. Preferably the ZrO2 is between 50 and 90 vol % of the total metal oxide content of the binder phase, even more preferably the ZrO2 is between 70 and 90 vol % of the total metal oxide content of the binder phase.
According to some aspects, the Al2O3 is between 5 and 25 vol % of the total binder phase. Preferably the Al2O3 is between 5 and 15 vol % of the total binder phase. According to one embodiment, further constituents may be comprised in the binder phase, e.g. TiC or other conventionally used constituents. However, the binder phase preferably consists of metal oxides and metal nitrides as further specified herein.
According to some aspects, the PCBN body is backed with a backing body of cemented carbide.
According to some aspects, the PCBN body is coated with a PVD- or CVD coating having a thickness of between 0.8 μm and 15 μm.
According to some aspects, the PCBN body is coated with a PVD coating comprising a first (Ti,Al)-based nitride sub-coating being a single (Ti1-xAlx)Nz-layer where 0.1<x<0.4, 0.6<z<1.2 and a second (Ti,Al)-based nitride sub-coating being a laminated structure comprising a (Ti1-x1-y1Alx1Cry1)Nz1-layer where 0.5<x1<0.75, 0.05<y1<0.2, 0.6<z1<1.2. Preferably the first (Ti,Al)-based nitride sub-coating has a thickness between 0.1 μm and 2 μm. The second (Ti,Al)-based nitride sub-coating having a laminated structure may consist of alternating A and B layers: A/B/A/B/A/B/ . . . , where layer A is (Ti1-xAlx)Nz, 0.1<x<0.4, 0.6<z<1.2, and layer B is (Ti1-x1-y1Alx1Cry1)Nz1, 0.5<x1<0.75, 0.05<y1<0.2, 0.6<z1<1.2. Preferably the second (Ti,Al)-based nitride sub-coating has a laminated structure having a thickness between 0.5 μm and 10 μm, and the A and B layers of the laminated structure have an average individual layer thickness between 1 nm and 100 nm, preferably between 5 nm and 50 nm, most preferably between 5 nm and 30 nm.
According to some aspects, the PCBN body is coated with a PVD coating comprising a columnar and polycrystalline nano-laminated structure of alternating A and B layers, where layer A is (Ti1-xAlxMe1p)Na, with 0.3<x<0.95, preferably 0.45<x<0.75, 0.90<a<1.10, preferably 0.96<a<1.04, 0<p<0.15, and Me1 is one or more of Zr, Y, V, Nb, Mo and W, layer B is (Ti1-y-zSiyMe2z)Nb, with 0.05<y<0.25, preferably 0.05<y<0.18, 0≤ z<0.4, 0.9<b<1.1, preferably 0.96<b<1.04, and Me2 is one or more of Y, V, Nb, Mo, W and Al. The nano-laminated structure has a thickness between 0.5 μm and 10 μm, preferably between 0.5 μm and 5 μm, an average column width between 20 nm and 1000 nm, and an average individual thickness of A and B layers between 1 nm and 50 nm.
According to some aspects, the PCBN body is a cutting tool or a cutting tip of a cutting tool. The cutting tool is used for machining by chip removal, such as in turning, milling or drilling operations. Examples of cutting tools are indexable cutting inserts, solid drills and end mills.
The disclosure provides a method of manufacturing a PCBN body according to any of the above aspects, comprising the following steps:
According to one embodiment, metallic aluminium is added in an amount of 1 to 10 vol % or 1 to 5 vol % of the total amount of components added.
According to some aspects, the heat treating of the green body is performed at a temperature below 1100° C.
According to some aspects, the sintering, step of the green body is performed at a temperature below 2000° C.
According to some aspects, the manufactured solid sintered PCBN compact is thereafter cut into pieces by using electric discharge machining (EDM) or laser.
The disclosure provides a use of a PCBN body according to any of the aspects described above for machining in nickel based and/or cobalt based super alloys.
The invention will now be explained more closely by the description of different embodiments of the invention and with reference to the appended figures.
Aspects of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings. The device and method disclosed herein can, however, be realized in many different forms and should not be construed as being limited to the aspects set forth herein. Like numbers in the drawings refer to like elements throughout.
The terminology used herein is for the purpose of describing particular aspects of the disclosure only and is not intended to limit the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.
The term “cutting tool”, as used herein, is intended to denote cutting tools suitable for metal cutting by chip removal, such as turning, milling or drilling. Examples of cutting tools are indexable cutting inserts, solid drills and end mills.
Unless otherwise defined, all terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.
Common for cutting tools inserts is that they may be a solid body or a body comprising a backing body onto which an additional material is placed, either over the cutting edge on the rake face, a so-called tipped body, or such that it covers the full rake, a so-called full-face body.
The disclosure provides a sintered PCBN body 1, 2 comprising between 40 and 85 vol % of cubic boron nitride (cBN) particles and between 15 and 60 vol % of a binder phase, wherein the binder phase comprises at least one metal oxide and at least one metal nitride. The at least one metal oxide comprises between 20 and 100 vol % of zirconium oxide (ZrO2) and up to 80 vol % of alumina (Al2O3) counted as a volume percentage of the total metal oxide content of the binder. Further, the at least one metal nitride comprises aluminium nitride (AlN) and at least one of the metal nitrides selected from the group consisting of vanadium nitride (VN), niobium nitride (NbN) and hafnium nitride (HfN). The metal nitride content is at least 10 vol % of the binder phase.
The binder phase of the sintered PCBN body 1 may, for example, comprise at least one metal oxynitride being a reaction product of one of the at least one metal oxides and one of the at least one metal nitrides.
The binder phase may, for example, comprise at least one oxynitride selected from the group consisting of zirconium oxynitride (Zr(O,N)), zirconium vanadium oxynitride ((Zr,V)ON), zirconium niobium oxynitride ((Zr,Nb)ON) and zirconium hafnium oxynitride ((Zr,Hf)ON).
As an alternative or additionally, the oxynitride may, for example, comprise at least one oxynitride selected from the group consisting of aluminium oxynitride (Al(O,N)), aluminium vanadium oxynitride ((Al,V)ON), aluminium niobium oxynitride ((Al,Nb)ON) and aluminium hafnium oxynitride ((Al,Hf)ON).
The oxynitride and metal nitride content of at least one of vanadium nitride (VN), niobium nitride (NbN) and hafnium nitride (HfN) are, for example, between 10 and 50 vol % of the total binder phase.
According to an alternative example method the following steps are performed for manufacturing the PCBN body:
The solid sintered PCBN compact is, for example, cut into pieces by using EDM or laser. The cut pieces forming PCBN bodies 1, 2 may be brazed to a cemented carbide backing body 4 to form a cutting tool as seen in, for example,
According to an example embodiment the PCBN body 1, 2 was manufactured according to the above method and the PCBN body has about 60 vol % of cBN particles and a binder phase comprising ZrO2 (both cubic and tetragonal), Al2O3, AlN, VN and zirconium oxynitride (Zr(O,N)).
PCBN cutting tools according to an embodiment of the present disclosure with a composition corresponding to sample 1 in table 1 were produced according to the above alternative example embodiment of the manufacturing method. First comparative PCBN cutting tools with conventional TiC-binder having a composition according to sample 2 in table 1 and second comparative PCBN cutting tools with conventional TiCN-binder having a composition according to sample 3 in table 1, were produced under identical powder preparation and sintering conditions as sample 1.
The cutting tools were manufactured in ISO RNGN090300 insert geometry.
Longitudinal turning was performed on Inconel 718 workpiece material supplied in aged condition and having a hardness of HRC 45 with PCBN cutting tools having compositions according to sample 1-3.
The cutting data used were:
while depth of cut was ap=0.3 mm for both cases, corresponding to high-speed finishing conditions. High pressure directed cooling (HPDC) was applied and set for 90 bar coolant pressure at the rake and flank faces of the cutting tool, using 8% oil-water emulsion as coolant medium.
Flank wear was measured after spiral length of 950 meters which corresponded to the time in cut of 3.2 minutes for cutting speed vc=300 m/min and 2.7 minutes for cutting speed vc=350 m/min.
Flank wear was measured using Olympus SZX7 optical microscope.
In table 2 the measured flank wear for cutting speeds of 300 and 350 m/min are shown.
The SEM images in
From the experimental results and observations related to the example 1 it was concluded that PCBN cutting tool having a composition according to the present invention demonstrated more than 50% improvement in performance compared to the conventional TiC-binder and TiCN-binder.
Turning of a curved profile with curvature radius of R38.5 mm was performed on Inconel 718 workpiece material supplied in aged condition and having a hardness of HRC 45. PCBN cutting tools having the same composition as in example 1 were used, i.e. compositions according to sample 1-3 in table 1.
Three different cases of cutting data were used:
while depth of cut in all three cases was ap=0.3 mm, corresponding to high-speed finishing conditions. High pressure directed cooling (HPDC) was applied and set for 70 bar coolant pressure at the rake and flank faces of the cutting tool, using 8% oil-water emulsion as coolant medium.
The cutting tools were manufactured in ISO RNGN090300 insert geometry.
Flank and notch wear were measured in time intervals of 0.89 minutes ±0.11 minutes and the performance tests were stopped when either maximum flank wear exceeded the criterion of 250 μm or notch wear exceeded the criterion of 1000 μm.
The PCBN cutting tool with TIC as the main binder phase, i.e. sample 2 has rapidly developed a critical notch wear under cutting conditions of cutting speed vc=420 m/min at feed f=0.08 mm/rev and failed by edge fracture and is therefore not included in table 3 showing the tool wear for example 2.
Flank and notch wear was measured using Olympus SZX7 optical microscope.
Table 3 shows the measured flank wear at respective time-in-cut interval when flank or notch wear parameter has reached its limiting criterion for the three different set of cutting data used.
Table 4 shows the measured notch wear for the three different set of cutting data used.
The SEM images in
From the experimental results and observations related to the example 2 it was concluded that Sample 1, i.e. the PCBN cutting tool according to present disclosure, demonstrated more than 31% improvement in performance by flank wear criterion while providing more than 110% improvement by notch wear criterion compared to the conventional TiC-binder and TiCN-binder.
The present invention is not limited to the embodiments disclosed but may be varied and modified within the scope of the following claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21176226.5 | May 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/064267 | 5/25/2022 | WO |
